Epson C8 Series User manual

Rev.13 EM208R4413F
6-Axis Robots
C8 series
MANIPULATOR MANUAL

Manipulator manual C
8 series Rev.13

C8 Rev.13 i
6-Axis Robots
C8 series Manipulator Manual
Rev. 13
Copyright 2015-2020 SEIKO EPSON CORPORATION. All rights reserved.

ii C8 Rev.13
FOREWORD
Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the manipulator.
Please carefully read this manual and other related manuals before installing the robot
system.
Keep this manual handy for easy access at all times.
WARRANTY
The robot and its optional parts are shipped to our customers only after being subjected to
the strictest quality controls, tests, and inspections to certify its compliance with our high
performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please contact the supplier of your region for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1.
Damage or malfunction caused by improper use which is not described in the manual,
or careless use.
2.
Malfunctions caused by customers’ unauthorized disassembly.
3.
Damage due to improper adjustments or unauthorized repair attempts.
4.
Damage
caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1.
If the robot or associated equipment is used outside of the usage conditions and product
specifications described in the manuals, this warranty is void.
2.
If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be
responsible for any malfunction or accident, even if the result is injury or death.
3.
We cannot foresee all possible dangers and consequences. Therefore, this manual cannot
warn the
user of all possible hazards.

C8 Rev.13 iii
TRADEMARKS
Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries. Other brand and
product names are trademarks or registered trademarks of the respective holders.
NOTICE
No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
Please notify us if you should find any errors in this manual or if you have any comments
regarding its contents.
MANUFACTURER
CONTACT INFORMATION
Contact information is described in “SUPPLIERS” in the first pages of the following
manual:
Robot System Safety and Installation Read this manual first

iv C8 Rev.13
Regarding battery disposal
The crossed out wheeled bin label that can be found on your product indicates that this
product and incorporated batteries should not be disposed of via the normal household waste
stream. To prevent possible harm to the environment or human health please separate this
product and its batteries from other waste streams to ensure that it can be recycled in an
environmentally sound manner. For more details on available collection facilities please
contact your local government office or the retailer where you purchased this product. Use
of the chemical symbols Pb, Cd or Hg indicates if these metals are used in the battery.
This information only applies to customers in the European Union, according to
DIRECTIVE 2006/66/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and
accumulators and repealing Directive 91/157/EEC and legislation transposing and
implementing it into the various national legal systems.
For other countries, please contact your local government to investigate the possibility of
recycling your product.
The battery removal/replacement procedure is described in the following manuals:
Robot Controller manual / Manipulator manual (Maintenance section)

C8 Rev.13 v
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Control System
C8 Manipulators can be used with the following combinations of Controllers and software.
Controller : RC700-A
Software : EPSON RC+ 7.0 Ver.7.1.3 or later (C8XL)
EPSON RC+ 7.0 Ver.7.1.4 or later (C8, C8L)
EPSON RC+ 7.0 Ver.7.2.0 or later (wall mounting)
Setting by Software
EPSON
RC+
This manual contains setup procedures using the software.
Those sections are indicated by the symbol on the left.
Turning ON/OFF Controller
When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to turn
ON/OFF all the hardware components.
Photos and Illustrations Used in This Manual
The appearance of some parts may differ from those on an actual product depending on
when it was shipped or the specifications. The procedures themselves, however, are accurate.

vi C8 Rev.13

Table of Contents
C8 Rev.13 vii
Setup & Operation
1. Safety 3
1.1 Conventions............................................................................................3
1.2 Design and Installation Safety................................................................4
1.3 Operation Safety ....................................................................................5
1.4 Emergency Stop.....................................................................................7
1.5 How to Move Arms with the Electromagnetic Brake..............................9
1.5.1 Moving the Arm using the brake release unit...........................10
1.5.2 Moving the Arm using the software..........................................10
1.6 Precaution for Operation in Low Power Status....................................10
1.7 Warning Labels.....................................................................................11
2. Specifications 13
2.1 Features of Manipulators .....................................................................13
2.2 Model Number......................................................................................14
2.3 Part Names and Motion Range of Each Arm.......................................15
2.4 Outer Dimensions.................................................................................17
2.4.1 C8-A701*** (C8) .......................................................................17
2.4.2 C8-A901*** (C8L) .....................................................................18
2.4.3 C8-A1401*** (C8XL).................................................................19
2.5 Standard Motion Range .......................................................................20
2.5.1 C8-A701*** (C8) .......................................................................20
2.5.2 C8-A901*** (C8L) .....................................................................21
2.5.3 C8-A1401*** (C8XL).................................................................22
2.6 Specifications .......................................................................................23
2.6.1 Specifications table ..................................................................23
2.6.2 Option .......................................................................................27
2.7 How to Set the Model...........................................................................28
3. Environment and Installation 29
3.1 Environmental Conditions ....................................................................29
3.2 Unpacking, Transportation, and Relocation.........................................31
3.3 Mounting Dimensions...........................................................................34
3.3.1 Cable Backward Model ............................................................34
3.3.2 Cable Downward Model ...........................................................36
3.4 Installation ............................................................................................37
3.5 Connecting the Cables.........................................................................40
3.6 User Wires and Pneumatic Tubes........................................................42
Electrical wires .....................................................................................43
Pneumatic tubes ..................................................................................44
3.7 Checking the Basic orientation.............................................................45

Table of Contents
viii C8 Rev.13
4. End Effectors 46
4.1 Attaching an End Effector ....................................................................46
4.2 Attaching Camera and Air Valves ........................................................46
4.3 WEIGHT and INERTIA Settings...........................................................48
4.3.1 WEIGHT setting .......................................................................50
4.3.2 INERTIA setting........................................................................54
4.4 Precautions for Auto Acceleration/Deceleration ..................................59
5. Motion Range 60
5.1 Motion Range Setting by Pulse Range (for Each Joint)......................60
5.1.1 Max. Pulse Range of Joint #1..................................................61
5.1.2 Max. Pulse Range of Joint #2..................................................61
5.1.3 Max. Pulse Range of Joint #3..................................................62
5.1.4 Max. Pulse Range of Joint #4..................................................62
5.1.5 Max. Pulse Range of Joint #5..................................................63
5.1.6 Max. Pulse Range of Joint #6..................................................63
5.2 Motion Range Setting by Mechanical Stops........................................64
5.2.1 Motion Range Setting of Joint #1.............................................64
5.2.2 Motion Range Setting of Joint #2.............................................65
5.2.3 Motion Range Setting of Joint #3.............................................66
5.3 Restriction of Manipulator Operation by Joint Angle Combination......67
5.4 Coordinate System...............................................................................71
5.5 Changing the Robot .............................................................................72
5.6 Setting the Cartesian (Rectangular) Range
in the XY Coordinate System of the Manipulator ................................73
6. Options 74
6.1 Brake Release Unit ..............................................................................74
Mount the brake release unit ...............................................................76
Remove the brake release unit............................................................76
How to use the brake release unit .......................................................77
6.2 Camera Plate Unit................................................................................78
6.3 Tool Adapter (ISO Flange) ...................................................................80
6.4 Adjustable Mechanical Stops...............................................................81
6.5 User Wires and Pneumatic Tubes .......................................................82

Table of Contents
C8 Rev.13 ix
Maintenance
1. Safety Maintenance 85
2. General Maintenance 86
2.1 Maintenance Inspection .......................................................................86
2.1.1 Schedule for Maintenance Inspection......................................86
2.1.2 Inspection Point........................................................................87
2.2 Overhaul (Parts Replacement).............................................................89
2.3 Greasing ...............................................................................................91
2.3.1 Joint #1 Reduction Gear Unit (Table Top Mounting) ................93
2.3.2 Joint #1 Reduction Gear Unit
(Ceiling Mounting, Wall mounting) ............................................94
2.3.3 Joint #2 Reduction Gear Unit ...................................................95
2.3.4 Joint #3 Reduction Gear Unit ...................................................96
2.3.5 Joint #4 Reduction Gear Unit ...................................................97
2.3.6 Joint #5 Reduction Gear Unit ...................................................98
2.3.7 Joint #6 Reduction Gear Unit ...................................................99
2.3.8 Joint #6 Bevel Gear............................................................... 100
2.4 Tightening Hexagon Socket Head Bolts ........................................... 101
2.5 Layout of Maintenance Parts ............................................................ 102
3. Covers 103
3.1 Arm #1 Center Cover ........................................................................ 106
3.2 Arm #1 Side Cover ............................................................................ 107
3.3 Arm #2 Side Cover ............................................................................ 109
3.4 Arm #3 Cover .....................................................................................110
3.5 Arm #3 Maintenance Cover ............................................................... 111
3.6 Arm #4 Side Cover .............................................................................113
3.7 Arm #4 Maintenance Cover (C8XL only) ...........................................115
3.8 Arm #4 D-sub Attachment ..................................................................117
3.9 Base Cover ...........................................................................................118
3.9.1 M/C Cable Backward..............................................................118
3.9.2 M/C Cable Downward ............................................................119
3.10 Base Maintenance Cover................................................................ 123
3.11 Connector Plate............................................................................... 125
3.11.1 M/C Cable Backward........................................................... 125
3.11.2 M/C Cable Downward.......................................................... 129
3.12 Connector Sub Plate ....................................................................... 130

Table of Contents
x C8 Rev.13
4. Cable Unit 132
4.1 Replacing the Cable Unit ...................................................................132
4.1.1 Replacing the Cable Unit (M/C Cable Backward)..................134
4.1.2 Replacing the Cable Unit (M/C Cable Downward) ................164
4.2 Connector Pin Assignment.................................................................169
4.2.1 Signal Cable...........................................................................169
4.2.2 Power Cable...........................................................................172
4.2.3 User Cable .............................................................................175
4.2.4 Color of Cables.......................................................................175
5. Joint #1 176
5.1 M/C Cable Backward (Joint #1) .........................................................177
5.1.1 Joint #1 - Replacing the Motor (M/C Cable Backward) .........177
5.1.2 Joint #1 - Replacing the Reduction Gear Unit
(M/C Cable Backward)............................................................185
5.1.3 Joint #1 - Replacing the Timing Belt (M/C Cable Backward).192
5.1.4 Joint #1 - Replacing the Electromagnetic Brake
(M/C Cable Backward)............................................................199
5.2 M/C Cable Downward (Joint #1)........................................................201
5.2.1 Joint #1 - Replacing the Motor (M/C Cable Downward) ........201
5.2.2 Joint #1 - Replacing the Reduction Gear Unit
(M/C Cable Downward)...........................................................205
5.2.3 Joint #1 - Replacing the Timing Belt (M/C Cable Downward)208
5.2.4 Joint #1 - Replacing the Electromagnetic Brake
(M/C Cable Downward)...........................................................213
6. Joint #2 216
6.1 Joint #2 - Replacing the Motor...........................................................217
6.2 Joint #2- Replacing the Reduction Gear Unit ....................................226
6.3 Joint #2 - Replacing the Timing Belt ..................................................233
6.4 Joint #2 - Replacing the Electromagnetic Brake................................234
7. Joint #3 235
7.1 Joint #3 - Replacing the Motor...........................................................236
7.2 Joint #3 - Replacing the Reduction Gear Unit ...................................244
7.3 Joint #3 - Replacing the Timing Belt ..................................................250
7.4 Joint #3 - Replacing the Electromagnetic Brake................................251
8. Joint #4 252
8.1 Joint #4 - Replacing the Motor...........................................................253
8.2 Joint #4 - Replacing the Reduction Gear Unit ...................................259
8.3 Joint #4 - Replacing the Timing Belt ..................................................266
8.4 Joint #4 - Replacing the Electromagnetic Brake................................272

Table of Contents
C8 Rev.13 xi
9. Joint #5 273
9.1 Joint #5 - Replacing the Motor .......................................................... 274
9.2 Joint #5 - Replacing the Reduction Gear Unit
(Replacing the Joint #5, #6 Reduction Gear Unit Set) ..................... 281
9.3 Joint #5 - Replacing the Timing Belt ................................................. 287
9.4 Joint #5 - Replacing the Electromagnetic Brake............................... 288
10. Joint #6 290
10.1 Joint #6 - Replacing the Motor ........................................................ 291
10.2 Joint #6 - Replacing the Reduction Gear Unit
(Replacing the Joints #5, #6 Reduction Gear Unit Set).................... 297
10.3 Joint #6 - Replacing the Timing Belt ............................................... 298
10.4 Joint #6 - Replacing the Electromagnetic Brake............................. 299
11. Replacing the Battery Unit 301
11.1 Replacing the Battery Unit (Lithium Battery)................................... 303
11.2 Replacing the Battery Board ........................................................... 305
12. Replacing the Control Board 308
12.1 Replacing the Control Board 1........................................................ 309
12.2 Replacing the Control Board 2.........................................................311
13. Replacing the LED Lamp 313
14. Replacing the M/C Cable 315
15. Replacing the Fan 319
16. Calibration 321
16.1 Overview.......................................................................................... 321
16.2 Calibration Procedure...................................................................... 324
17. Maintenance Parts List 328
18. Option Parts List 332

Table of Contents
xii C8 Rev.13

Setup & Operation
This volume contains information for setup and operation of the Manipulators.
Please read this volume thoroughly before setting up and operating the Manipulators.

Setup & Operation 1. Safety
C8 Rev.13 3
1. Safety
Installation and transportation of the Manipulators and robotic equipment shall be
performed by qualified personnel and should conform to all national and local codes.
Please read this manual and other related manuals before installing the robot system or
before connecting cables.
Keep this manual handy for easy access at all times.
1.1 Conventions
Important safety considerations are indicated throughout the manual by the following
symbols. Be sure to read the descriptions shown with each symbol.
WARNING
This symbol indicates that a danger of possible serious injury or
death exists if the associated instructions are not followed
properly.
WARNING
This symbol indicates that a danger of possible harm to people
caused by electric shock exists if the associated instructions are
not followed properly.
CAUTION
This symbol indicates that a danger of possible harm to people
or physical damage to equipment and facilities exists if the
associated instructions are not followed properly.

Setup & Operation 1. Safety
4 C8 Rev.13
1.2 Design and Installation Safety
Only trained personnel should design and install the robot system. Trained
personnel are defined as those who have taken robot system training and
maintenance training classes held by the manufacturer, dealers, or local
representative companies, or those who understand the manuals thoroughly and
have the same knowledge and skill level as those who have completed the training
courses.
To ensure safety, a safeguard must be installed for the robot system. For details
on the safeguard, refer to the Installation and Design Precautions in the Safety
chapter of the EPSON RC+ User’s Guide.
The following items are safety precautions for design personnel:
WARNING
■
Personnel who design and/or construct the robot system with this product must
read the
Safety chapter in the EPSON RC+ User’s Guide. Designing and/or
constructing the robot system without understanding the saf
ety requirements is
extremely hazardous, and may result in serious bodily injury and/or severe
equipment damage to the robot system.
■
The Manipulator and the Controller must be used within the environmental
conditions described in their
respective manuals. This product has been
designed and manufactured strictly for use in a normal indoor environment.
Using the product in an environment that exceeds the specified environmental
conditions may not only shorten the life of the product but
may also cause serious
safety problems.
■
The robot system must be used within the installation requirements described in
the manuals. Using the robot system outside of the installation requirements
may not only shorten the life of the product but also
cause serious safety
problems.
Further precautions for installation are described in the chapter Setup & Operation
3. Environment and Installation. Please read this chapter carefully to understand
safe installation procedures before installing the robots and robotic equipment.

Setup & Operation 1. Safety
C8 Rev.13 5
1.3 Operation Safety
The following items are safety precautions for qualified Operator personnel:
WARNING
■
Please carefully read the
Safety-related Requirements in the Safety chapter of the
Safety and Installation
manual
. Operating the robot system without
understanding the safety requirements is extremely hazardous and may result in
serious bodily injury and/or severe equipment damage to the robot system.
■
Do not enter the operating ar
ea of the Manipulator while the power to the robot
system is turned ON. Entering the operating area with the power ON is
extremely hazardous and may cause serious safety problems as the Manipulator
may move even if it seems to be stopped.
■
Before operating the robot system, make sure that no one is inside the
safeguarded area. The robot system can be operated in the mode for teaching
even when someone is inside the safeguarded area.
The motion of the Manipulator is always in restricted status (low
speeds and low
power) to secure the safety of an operator. However, operating the robot system
while someone is inside the safeguarded area is extremely hazardous and may
result in serious safety problems in case that the Manipulator moves
unexpectedly.
■
Immediately press the Emergency Stop switch whenever the Manipulator moves
abnormally
during operation. Continuing the operation while the Manipulator
moves abnormally is extremely hazardous and may result in serious bodily injury
and/or severe equipm
ent change to the robot system.
WARNING
■
Be sure to connect the AC power cable to a power receptacle. DO NOT connect
it directly to a factory power source. To shut off power to the robot system,
disconnect
the power plug from the power source. Performing any work while
connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
■
Before
performing any replacement procedure, turn OFF the Controller and
related equipment,
and then disconnect the power plug from the power source.
Performing any replacement procedure with the power ON is extremely hazardous
and may result in
electric shock and/or malfunction of the robot system.
■
Do not connect or disconnect the motor connectors while the power to the robot
system is turned ON. Connecting or disconnecting the motor connectors
with
the power ON is extremely hazardous and may result
in serious bodily injury as
the Manipulator may mo
ve abnormally, and also may result in electric shock
and/or malfunction of the robot system.

Setup & Operation 1. Safety
6 C8 Rev.13
CAUTION
■
Whenever possible, only one person should operate the robot system.
If it is
necessary to operate the robot system with more than one person, ensure that all
people involved communicate with each other as to what they are doing and take
all necessary safety precautions.
■
If the joints are operated repeatedly with the operating angle less than 5 degrees,
they may get damaged early because the bearings are likely to cause oil film
shortage in such situation. To prevent early breakdown, move the joints larger
than
30 degrees for about five to ten times a day.
■
Oscillation (resonance) may
occur continuously in low speed Manipulator motion
(Speed:
approx. 5 to 20%) depending on combination of Arm orientation and end
effector load.
Oscillation arises from natural oscillation frequency of the Arm and
can be co
ntrolled by following measures.
Changing Manipulator speed
Changing the teach points
Changing the end effector load